Disk brake pad assembly and caliper assembly

Description

BACKGROUND OF THE INVENTION

[0001] The present invention relates generally to brake pads for use with vehicle brake calipers, and more specifically, the invention relates to brake pad backing plates. The present invention also relates to caliper assemblies.

[0002] Disc braking systems use brake pads which have a custom manufactured metal backing plate attached to a friction lining. The backing plate creates a surface which helps the friction lining withstand the reaction force or vibrational impact caused by the road as the brake pads engage the rotor. Friction linings are commonly attached to the surface of a backing plate by rivets. The rivets are received within numerous recesses in the braking surface of the lining. Additionally, locators on the backing plate locate the brake pad relative to the caliper to prevent rotation of the brake pad when the piston is engaged.

[0003] Prior art backing plates have several drawbacks. The backing plates are usually manufactured from plates of steel, which requires expensive tooling. Backing plates are specifically manufactured for each brake design, requiring a different backing plate and tooling for different linings.

[0004] An alternative design for a disc brake pad assembly according to the preamble of claim 1 can be seen in publication JP06081864 (Toyota).

[0005] The thickness of the friction lining decreases over the life of the brake pads due to wear. As a result, the rivets gradually approach the braking surface. A common problem with utilizing rivets is the incidents of the rivets scoring the brake rotors when the friction linings wear down. Additionally, the rivets significantly reduce the surface area of the friction lining which contacts the brake rotor.

[0006] Hence, there is a need in the art for a brake pad which does not require custom backing plates that must be riveted to the friction lining.

SUMMARY OF THE INVENTION

[0007] An inventive embodiment includes a metal friction lining support affixed on or just under the surface of a friction lining. The support is symmetrical such that it can be affixed to either of the corners of the friction lining.

[0008] The friction lining support is L-shaped and includes a perpendicular extension which locates the friction lining relative to the caliper housing. The support can be affixed to any friction lining, regardless of size, since the support is universal and configured to fit in the corner of a friction lining of any size.

[0009] The friction lining support includes attachment features like for instance holes or protrusions located on the surface of the support. The holes or protrusion assist in affixing the support to the friction lining by molding the support in the friction lining and provide more useable lining material compared to rivet fasteners.

[0010] Accordingly, the present invention provides a friction lining support composed of metal which is affixed to or just under the surface of a friction lining to create a surface which withstands the reaction force or vibration impact caused by road input.

[0011] These and other features of the present invention will be best understood from the following specification and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The various features and advantages of the invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment.

[0013] The drawings that accompany the detailed description can be briefly described as follows:

Figure 1 illustrates a cross-sectional view of a prior art caliper housing disc brake assembly.

Figure 2 is a schematic view of a friction lining with an affixed pair of friction lining supports.

Figure 3 illustrates a schematic view of a friction lining support with an extension.

Figure 4 illustrates a side view of a friction lining with an affixed pair of friction lining supports with extensions.

Figure 5 illustrates a schematic view of a friction lining support with an extension affixed to a brake pad, the extension of the friction lining support locating the brake pad relative to the caliper housing to prevent rotation.

Figure 6 illustrates a schematic view of a friction lining support.

Figure 7 illustrates a side view of a friction lining with an affixed pair of friction lining supports.

Figure 8 illustrates a schematic view of a friction lining support with holes.

Figure 9 illustrates a schematic view of a friction lining support with protrusions.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0014] Figure 1 illustrates a cross-sectional view of a prior art caliper disc brake assembly 10. The caliper housing disc brake assembly 10 generally includes a caliper housing 12 which bridges a rotor 14. The rotor 14 carries the wheel (not shown) and rotates in combination with it. The caliper housing 12 includes an outboard leg 16 on the outboard side 18 of the rotor 14 and an inboard leg 20 on the inboard side 22 of the rotor 14. The inboard leg 20 further includes a piston 24 which is mounted for movement towards the inboard side 22 of the rotor 14.

[0015] Brake pads 25 are arranged on either side of the rotor 14 and engage the rotor 14 when the piston 24 is actuated by the brake pedal (not shown). In prior art caliper disc brake assemblies, the brake pads 25 include a friction lining 26 and a custom metal backing plate 28. The metal backing plate 28 is placed under each friction lining 26 to resist wear and vibrations. The brake pads 25 are positioned on both the piston 24 and the outboard leg 16 in order to engage the rotor 14. If the backing plate 28 were eliminated, the friction linings 26 would not be able to withstand the reaction force or vibration impact due to road input into the brake. On the inboard leg 20 of the caliper housing 12, a load distribution plate 30 is placed under the backing plate 28 to provide additional support for the friction lining 26.

[0016] As shown in Figure 2, a universal support 32 is affixed at adjacent corners 36 of the friction lining 26. The support 32 is molded either on or just under the outer surface 34 of the friction lining 26. The dimensions of the support 32 allow it to be used on different lining assembly sizes because the support 32 is configured to fit in the corner 36 of a friction lining 26 of various sizes.

[0017] The support 32 is symmetrical such that is can be affixed to a corner 36 of the friction lining 28. The support 32 is affixed to the friction lining 26 such that the exterior corner 38 of the support 32 is substantially proximate to one of the corners 36 of the friction lining 26. At this location, the support 32 is able to react against the caliper housing 12 due to brake torque and prevent rotation of the friction lining 26.

[0018] As shown in Figures 3 and 4, the support 32 is composed of metal and is substantially L-shaped. The support 32 further includes an extension 44 attached perpendicularly to the exterior edge 46 of the support 32, such that the extension 44 projects away from the friction lining 26.

[0019] As shown in Figure 5, the extensions 44 contact the caliper housing 12 in order to locate the friction lining 26 with respect to the caliper housing 12. As the piston 24 is engaged, various forces will cause the friction lining 26 to rotate. The extensions 44 prevent this rotation by contacting the caliper housing 12 as the piston 24 is engaged.

[0020] Figures 6 and 7 illustrate an alternative embodiment of the present invention. In this embodiment, the support 32 is planar and does not include extensions 44.

[0021] The support 32 does not have to be manufactured of plate stock, so the support 32 can include additional features. As shown in Figures 8 and 9, various attachment features, such as holes 40 or protrusions 42 can be added to the surface 48 of the support 32 to assist in molding the friction lining 26 around the support 32.

[0022] By using a support 32 to resist wear and vibrations, a prior art backing plate 28 need not be utilized. Since the support 32 is universal and standard in size, it can be used on numerous lining assembly sizes. Prior art braking systems commonly used custom backing plates 28. Backing plates 28 are expensive, very detailed, and must be specifically manufactured for each brake design. The support 32 of the present invention would be made of less expensive plate stock, allowing the addition of other features, such as holes 40 and protrusions 42. Accordingly, the present invention provides a universal support 32 affixed to one of the corners 36 of a friction lining 26 to provide resistance to wear and vibrations caused by the road, eliminating the need of a backing plate 28.

[0023] The foregoing description is exemplary rather than defined by the limitations within. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed, however, so that one of ordinary skill in the art would recognize that certain modifications would come within the scope of this invention. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specially described. For that reason the following claims should be studied to determine the true scope and content of this invention.

Claims

1. A disc brake pad assembly comprising:

a friction lining (26) assembly having an outer caliper surface; and a pair of spaced apart friction lining supports (32) having a lining portion, characterised in that each support includes an attachment feature (40, 42) to affix said friction lining at said lining portion, wherein at least one of said supports is L-shaped, the or each support further comprising an exterior edge and an extension (44) attached perpendicularly to said support at said exterior edge, said extension locating said disc brake pad relative to a caliper and preventing rotation of said disc brake pad during braking.

2. The assembly as recited in claim 1 wherein said friction lining has a pair of corners, said friction lining supports each having an exterior corner (38) substantially proximate to one of said corners of said friction lining.

3. The assembly as recited in any preceding claim wherein said supports are formed of metal.

4. The assembly as recited in any preceding claim wherein said lining portion of at least one said supports is affixed to said caliper surface of said friction lining.

5. The assembly as recited in any preceding claim wherein said lining portion of at least one of said supports is affixed slightly under said caliper surface of said friction lining.

6. The assembly as recited in any preceding claim wherein said friction lining surrounds said lining portion of at least one of said supports.

7. The assembly as recited in any preceding claim wherein said attachment feature of at least one of said lining portions further comprises a plurality of holes (40) with portions of the friction lining disposed therein to attach said support to said friction lining.

8. The assembly as recited in any one of claims 1 to 6 wherein said attachment feature of at least one of said lining portions further comprises a plurality of protrusions (42) to attach said support to said friction lining.

Ansprüche

1. Scheibenbremsenbelag umfassend:

eine Reibbelageinheit (26) mit einer äußeren Sattelfläche und ein Paar beabstandeter Reibbelagträger (32) mit einem Belagabschnitt, dadurch gekennzeichnet, dass jeder Träger ein Befestigungselement (40, 42) aufweist, um den Reibbelag an dem Belagabschnitt zu befestigen, wobei mindestens einer der Träger L-förmig ist, wobei der oder jeder Träger ferner eine Außenkante und eine Erweiterung (44) aufweist, die senkrecht zu dem Träger an der Außenkante befestigt ist, wobei die Erweiterung den Scheibenbremsenbelag zu einem Sattel anordnet und das Drehen des Scheibenbremsenbelags während des Bremsens verhindert.

2. Einheit nach Anspruch 1, wobei der Reibbelag ein Paar Ecken hat, wobei die Reibbelagträger jeweils eine Außenecke (38) haben, die im Wesentlichen neben einer der Ecken des Reibbelags liegt.

3. Einheit nach einem der vorhergehenden Ansprüche, wobei die Träger aus Metall ausgebildet sind.

4. Einheit nach einem der vorhergehenden Ansprüche, wobei der Belagabschnitt mindestens eines der Träger an der Sattelfläche des Reibbelags befestigt ist.

5. Einheit nach einem der vorhergehenden Ansprüche, wobei der Belagabschnitt mindestens eines der Träger leicht unter der Sattelfläche des Reibbelags befestigt ist.

6. Einheit nach einem der vorhergehenden Ansprüche, wobei der Reibbelag den Belagabschnitt mindestens eines der Träger umgibt.

7. Einheit nach einem der vorhergehenden Ansprüche, wobei das Befestigungselement mindestens eines der Belagabschnitte mehrere Löcher (40) aufweist, wobei Abschnitte des Reibbelags darin angeordnet sind, um den Träger an dem Reibbelag zu befestigen.

8. Einheit nach einem der Ansprüche 1 bis 6, wobei das Befestigungselement mindestens eines der Belagabschnitte ferner mehrere Vorsprünge (42) zum Befestigen des Trägers an dem Reibbelag aufweist.

Revendications

1. Ensemble de garniture de frein à disque, comportant :

un ensemble de revêtement (26) de frottement présentant une surface extérieure d'étrier ; et une paire de supports (32) espacés de revêtement de frottement dotés d'une partie de revêtement, caractérisés en ce que chaque support comprend une entité (40, 42) de fixation destinée à rattacher ledit revêtement de frottement au niveau de ladite partie de revêtement, au moins un desdits supports présentant la forme d'un L, le ou chaque support comportant en outre un bord extérieur et un prolongement (44) fixé perpendiculairement audit support au niveau dudit bord extérieur, ledit prolongement positionnant ladite garniture de frein à disque par rapport à un étrier et empêchant la rotation dudit disque de frein pendant le freinage.

2. Ensemble selon la revendication 1, ledit revêtement de frottement présentant une paire de coins, lesdits supports de revêtement de frottement présentant chacun un coin extérieur (38) sensiblement voisin de l'un desdits coins dudit revêtement de frottement.

3. Ensemble selon l'une quelconque des revendications précédentes, lesdits supports étant formés de métal.

4. Ensemble selon l'une quelconque des revendications précédentes, ladite partie de revêtement d'au moins un desdits supports étant rattachée à ladite surface d'étrier dudit revêtement de frottement.

5. Ensemble selon l'une quelconque des revendications précédentes, ladite partie de revêtement d'au moins un desdits supports étant rattachée légèrement au-dessous de ladite surface d'étrier dudit revêtement de frottement.

6. Ensemble selon l'une quelconque des revendications précédentes, ledit revêtement de frottement entourant ladite partie de revêtement d'au moins un desdits supports.

7. Ensemble selon l'une quelconque des revendications précédentes, ladite entité de fixation d'au moins une desdites parties de revêtement comportant en outre une pluralité de trous (40) dans lesquels sont disposées des parties du revêtement de frottement afin de fixer ledit support audit revêtement de frottement.

8. Ensemble selon l'une quelconque des revendications 1 à 6, ladite entité de fixation d'au moins une desdites parties de revêtement comportant en outre une pluralité de protubérances (42) destinées à fixer ledit support audit revêtement de frottement.

Drawing